Alternative I-Stud

ABSTRACT

An i-stud having a web and flanges comprising oriented strand board (OSB) and a method of assembling a wall utilizing the same, wherein the flanges are unitary and non-laminated. The method of assembling a wall may utilize a wall system comprising upper and lower frame members or may utilize existing structural members.

CROSS-REFERENCE TO RELATED APPLICATIONS

None

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to materials and methods forwall construction. Specifically, the invention relates to studsfabricated in the shape of an “I” utilizing exclusively oriented strandboard, and to methods for assembling a wall using the same.

2. Description of the Prior Art

Construction materials of varying types are well known in the art. Formany years, lumber and steel have been used for studs. Studs arecommonly understood to be the relatively slender, upright membersforming the frame of a wall or partition and covered with drywall,sheetrock, plasterwork, siding, or other finishing material.Traditionally, solid, rectangular studs were made using dimensionallumber products.

Construction materials comprising engineered wood products andstructural composite lumber such as oriented strand board (OSB) aregaining in acceptance and popularity. U.S. Pat. No. 6,772,572 toHenthorn is directed to a fabricated OSB stud. It is likewise known toassemble a stud in the form of an “I” using multiple pieces. NASCOR®(Nascor, Inc., Calgary, Alberta, CANADA) manufactures I-joists (alsoreferred to as I-studs) having two dimensional lumber flanges separatedby an OSB web, the same being used in the NASCOR® III and IV WallSystem. Wood I Beam® joists (Georgia-Pacific Corp., Atlanta, Ga.)utilize FiberStrong® (Georgia-Pacific Corp., Atlanta, Ga.) OSB websfitted into solid lumber, sawn lumber or laminated veneer lumber (LVL)flanges. None of these products, however, utilizes OSB for both the weband the flanges.

U.S. Pat. No. 6,012,262 to Irving describes an assembled I-beam havingan OSB web situated between, and in grooves defined by, a pair oflaminated, two-piece OSB flanges. Each flange comprises an inner flangeand a reinforcing outer flange, these sub-parts being laminatedtogether. It is fairly well recognized that OSB does not have thetensile strength to resist the bending moment on a joist. Although thisassembly may provide added strength for a joist, such a constructionrequires both additional materials and additional labor to achieve thisconstruction and does not meet the need for an improved stud.

A need exists for an improved I-stud made exclusively of OSB, includingunitary and non-laminated OSB flanges, that is yet another suitablealternative to dimensional solid lumber studs and offers all of thebenefits of steel while remaining cost effective.

SUMMARY OF THE INVENTION

The present disclosure relates to a novel construction material andmethod for construction. More specifically, the disclosure is concernedwith an I-stud manufactured using exclusively oriented strand board(OSB), and a method of assembling a wall using the same.

It is a first object of the present invention to provide a material forconstruction that is stronger than light gauge steel cold formed studs,yet lighter than lumber studs, and more cost efficient than either, anda method of using the same.

It is a further object of the present invention to provide a materialfor construction that uses less wood than traditional lumber studs andis reliably straight while resisting warping, twisting and bowing, and amethod of using the same.

It is yet a further object of the present invention to provide amaterial for construction that does not interfere with wirelesscommunication, is resistant to heat and cold transfer, and can betreated to inhibit microbial growth, and a method of using the same.

It is a further object still of the present invention to provide amaterial for construction that does not require blocking in order tosupport cabinets, fixtures or trim, and a method of using the same.

Yet another object of the invention is to provide a material forconstruction that can be manufactured from up to 100% reclaimed productand from lower quality natural products, and a method of using the same.

It is yet another object of the present invention to provide a materialfor construction that can be fire resistance treated to meet prevalentbuilding codes, and a method of using the same.

Another object of the invention is to provide a wall systemincorporating the construction materials disclosed herein.

Other objects, features, and advantages of the present invention will bereadily appreciated from the following description. The descriptionmakes reference to the accompanying drawings, which are provided forillustration of the preferred embodiment. However, such embodiment doesnot represent the full scope of the invention. The subject matter whichthe inventor does regard as his invention is particularly pointed outand distinctly claimed in the claims at the conclusion of thisspecification.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the apparatus of thepresent disclosure.

FIG. 2 is an exploded view of the apparatus depicted in FIG. 1.

FIG. 3 is a perspective view of an alternative embodiment of theapparatus of the present disclosure.

FIG. 4 is a perspective view of an embodiment of the system of thepresent disclosure.

FIG. 5 is a perspective view of an alternative embodiment of the systemof the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED AND OTHER EMBODIMENTS

While the making and using of various embodiments of the presentdisclosure are discussed in detail below, it should be appreciated thatthe present disclosure provides for inventive concepts capable of beingembodied in a variety of specific contexts. The specific embodimentsdiscussed herein are merely illustrative of specific manners in which tomake and use the disclosed apparatus and are not to be interpreted aslimiting the scope of the instant disclosure.

In FIGS. 1 and 2, a stud 10 is depicted. Stud 10 comprises a web 12 andflanges 14, 16, such that when viewed from one end or in cross-section,stud 10 resembles an “I”. Thus, stud 10 may interchangeably be referredto herein as an i-stud. Each of web 12 and flanges 14, 16 aremanufactured using oriented strand board (OSB). Flanges 14, 16 are ofunitary, one-piece construction and are not laminated. Each flange 14,16 has a longitudinal channel or groove 18, 20 that is roughly centrallylocated about a face of the flange and runs the length thereof. Grooves18, 20 are preferably formed or machined to receive and frictionallyengage opposite ends of web 12. Grooves 18, 20 and opposite ends of web12 are preferably complementarily trapezoidal in shape. In a preferredembodiment, the depth of each groove 18, 20 is approximately one-halfthe thickness of flange 14, 16.

A bonding agent 22 is provided between web 12 and each groove 18, 20 toassemble stud 10. Bonding agent 22 may be any suitable agent, but ispreferably a phenolic resin or urea-formaldehyde. Bonding agent 22 maybut need not be the same as the bonding agent utilized in themanufacture of the underlying OSB components of stud 10. As is known theart, bonding agents 22 include drying adhesives as well asheat-activated adhesives.

Stud 10 may be provided with one or more apertures 24 through whichwiring, piping or other conduits may be passed or strung. Apertures 24may be any shape, including but not limited to round, ovoid, square andrectangular. Apertures 24 may also be any size subject to the limitationof the width of web 12 and, as is well known in the art, so as not tocompromise the structural integrity of web 12 and stud 10. Apertures 24are preferably rectangular and measure approximately 2¼ inches by 4inches in size, so as to accommodate a variety of conventional conduitsup to 2 inches in diameter. When multiple apertures 24 are provided,they may be provided at any interval but every 16 inches or so, oncenter (e.g., from the center of a first aperture 24 to the center ofthe adjacent aperture 24) along the length of web 12, is preferred.

An alternative embodiment is illustrated in FIG. 3, which depicts a stud10 having a plurality of spaced apart web members 26 disposedbetween—and along the length of—flanges 14, 16 in the same mannerdescribed above. Like web 12, web members 26 comprise oriented strandboard and are preferably of substantially the same thickness as flanges14, 16. The ends of web members 26 and grooves 18, 20 are alsopreferably complementarily trapezoidal in shape. It will be appreciatedthat in this embodiment, the need for apertures 24 is effectivelyeliminated, but one or more apertures 24 could be provided in individualweb members 26. Web members 26 may be distributed lengthwise about stud10 in any configuration, and may be any length relative to flanges 14,16, so long as the cumulative length of web members 26 in a given stud10 is less than the length of flanges 14, 16. Preferably, web members 26in a given stud 10 are each the same length, and are equidistantlyspaced.

Turning to FIG. 4, stud 10 is depicted as part of a wall system 28. Inaddition to a plurality of vertically oriented, spaced-apart studs 10,wall system 28 features horizontal upper frame member 30, horizontallower frame member 32, substantially in parallel, and a plurality ofbrackets 34 for joining studs 10 to the respective frame members.Brackets 34 are joined to flanges 14, 16 of studs 10 and frame members30, 32 using conventional fasteners 36 such as nails, rivets or screws.Either in combination with or in lieu of fasteners, each bracket 34 hasa plurality of clips 38 adapted to fit around, frictionally engage, andsecure flanges 14, 16 of stud 10. The number and orientation offasteners 36 may vary. Alternatively, it is conceivable that wall system28 may be nail-less.

With respect to FIG. 5, an alternative wall system 40 is shown. Inaddition to a plurality of vertically-oriented, spaced-apart studs 10,wall system 40 features horizontal upper frame member 42 and horizontallower frame member 44. Both upper and lower frame members 42, 44 arec-shaped channels adapted to receive and frictionally retain and secureopposite ends of stud 10. An additional conventional fastener 46 such asa nail, rivet or screw may be used to secure stud 10 to frame members42, 44.

Stud 10 may also be incorporated into conventional wall assemblies orattached directly to existing structural members such as floors,ceilings or joists. In this fashion, stud 10 may be used as areplacement material during repairs or renovation when an entire wall isnot being built or rebuilt. ‘Frame member’ as utilized herein shallinclude specific and/or manufactured components of a wall system asdescribed above, as well as existing, preferably horizontal andelongate, structural members that will serve as the upper or lower endof a wall to be built or replaced.

It will be appreciated by those skilled in the art that the use of studs10 in wall systems such as those disclosed herein will achievesubstantial cost savings over dimensional lumber or steel, withoutcompromising stability.

Thus, the present disclosure has been described in an illustrativemanner. It is to be understood that the terminology that has been usedis intended to be in the nature of words of description rather than oflimitation. Furthermore, whereas the present disclosure has beendescribed in relation to the drawings attached hereto, it should beunderstood that other and further modifications, apart from those shownor suggested herein, may be made within the spirit and scope of thisdisclosure.

1. An i-stud comprising: two unitary and non-laminated flanges eachhaving a longitudinal groove roughly centrally located about one side; aweb extending between said flanges, wherein opposite ends of said webare seated and frictionally engaged in said grooves; wherein said weband said flanges each comprise oriented strand board; and a bondingagent disposed between said opposite ends of said web and said grooves.2. The i-stud of claim 1 wherein said web and said flanges are ofsubstantially the same thickness.
 3. The i-stud of claim 1 wherein saidbonding agent is selected from the group consisting of phenolic resinand urea formaldehyde.
 4. The i-stud of claim 1 wherein said webcomprises an aperture.
 5. The i-stud of claim 4 wherein said webcomprises a plurality of apertures spaced apart approximately every 16inches, on center, along the length of said web.
 6. The i-stud of claim4 wherein said aperture is approximately 2¼ inches wide andapproximately 4 inches long.
 7. The i-stud of claim 1 wherein saidgrooves and said opposite ends of said web are complementary and roughlytrapezoidal in shape.
 8. An i-stud comprising: two unitary andnon-laminated flanges each having a longitudinal groove roughlycentrally located about one side; a plurality of spaced-apart webmembers extending between said flanges, wherein opposite ends of eachsaid web member are seated and frictionally engaged in said grooves;wherein said web members and said flanges each comprise oriented strandboard and are of substantially the same thickness; and a bonding agentdisposed between said opposite ends of said web members and saidgrooves.
 9. The i-stud of claim 8 wherein the sum of the lengths of saidweb members is less than the length of said flanges.
 10. A method ofassembling a wall, comprising the steps of: providing at least one framemember, and at least one stud, wherein said stud comprises two unitaryand non-laminated flanges each having a longitudinal groove roughlycentrally located about one side; a web extending between said flanges,wherein opposite ends of said web are seated and frictionally engaged insaid grooves; wherein said web and said flanges comprise oriented strandboard and are of substantially the same thickness; and a bonding agentdisposed between said opposite ends of said web and said grooves; andsecuring said at least one stud to at least one of said frame members.11. The method of claim 10 wherein said at least one stud is secured toat least one of said frame members using a fastener.
 12. The method ofclaim 10 further comprising the steps of: providing a bracket having aplurality of clips; securing said clips about said flanges of one ofsaid studs; and securing said bracket to one of said frame members. 13.The method of claim 12 further comprising the step of securing saidbracket to at least one of said flanges of said stud using a fastener.14. The method of claim 10 wherein said step of providing at least oneframe member comprises providing an upper frame member and a lower framemember.
 15. The method of claim 14 wherein said upper frame member andsaid lower frame member are elongate, horizontal and substantially inparallel.